“ There’s not a day that goes by that I don’t equate a savings in some shape or form with our safety systems!”, Mike Douglas, Sr. Manager & Consultant Global Health & Safety, Design, Standards & Technology
“ A historical lack of accidents does not imply a current presence of safety. It simply means you’ve been faster than the machine .”, Bill Hilton, Director of Health and Safety
“ We took an order in May for a new machine, and we were able to deliver it by the middle of September – half the time it previously took .”, Thomas Butler, Managing Director, T. Butler Engineering
“ Thanks to Rockwell Automation Integrated Architecture, we only require one supplier .”, Roggero Magagni, Commercial Manager, Barilla Ivano Ondenei, Software Engineer, Barilla
Influence - Safety standards allow safety automation products (“listed for such use”) to be used for safety-related functions since 2002.
White papers, case studies, & interviews
Example result - Using GuardLogix controllers instead of traditional safety relays helped GM greatly reduce installation and debug times for new body-shop equipment. Previously, wiring for a typical five-robot cell required 640 wires/cables; with the GuardLogix system, the wiring was reduced to a five-wire cable. Furthermore, the plug-and-play functionality and debug features reduced installation and maintenance time and costs. “GM’s Road To Safe Manufacturing””
Business metrics – can Overall Equipment Effectiveness (OEE) be applied?
Availability - Goal is to demonstrate that “integrated safety solutions” can reduce unscheduled downtime of a machine. This reduction can then be calculated into “unscheduled downtime savings” via the following variables:
Unscheduled Downtime per Week in minutes
Operations Cost of Downtime per minute(not including lost production)
Weeks of Unscheduled Downtime per year
Reduction Factor of all unscheduled downtime that is attributable to the proposed integrated safety solution. A default of 4% is built into the calculation (Aberdeen Group Study).
Note - Unscheduled downtime is caused by several factors such as; mechanical and "other" breakdowns, material shortages, scheduling issues, intermittent connections, miss-feeds, jams, operator or maintenance mistakes, etc.
Performance - Goal is to demonstrate that the “integrated safety solution” can improve the production levels of a machine by driving more machine "up time" and/or greater cycles per period (hour, shift, day, week, etc.). This increase in production can then be calculated into “increased profit” to the bottom line via the following variables:
Quality – Our research thus far has not supported a definitive relationship to first run quality produced parts as relates to the “integrated safety solution”. Therefore, we have not included any developed algorithms that would equate a quality impact to a company's balance sheet that directly relates to an “integrated safety solution” investment.
We are considering an updated ROI Tool revision that could address improved quality and the related improvements to the bottom line.